Numerical controller

ABSTRACT

A numerical controller having a learning control function executes commands in an NC program, starts performing learning control from a location where the same operation pattern starts occurring, and stops performing learning control at a location where the same operation pattern ends. Once a command that allows learning control is established in the NC program, the section in which learning control is carried out can be automatically determined.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a numerical controller for carrying outlearning control for controlling machine tools and other equipment.

2. Description of the Related Art

Learning control for improving machining accuracy is adopted whenrepeatedly commanding the same command pattern and executing the samecommand pattern in predetermined cycles to perform machining action. Inlearning control in which the same pattern is repeated in predeterminedcycles, the position deviation is sampled and the correction data for asingle cycle is stored on the basis of the position deviation, and, ofthe correction data, the correction data during sampling correspondingto the same command pattern is added to the position deviation duringthe current sampling to perform correction, as exemplified in JapanesePatent Application Laid-open No. 6-309021. This learning control isrepeatedly executed, the correction data is sequentially updated, andthe position deviation is ultimately brought to a value that isapproximately “0.” In this type of learning control, the positiondeviation is brought to a value that is approximately “0,” so highmachining accuracy can be achieved.

As described above, learning control repeatedly executes machining suchthat the same operation pattern is generated by the same commandpattern, so high precision machining can be carried out. Conventionally,however, this learning control is applied solely to binary operations inwhich the same operation pattern is generated, whereas in operation withan ordinary NC program (ISO/EIA format), the same operation pattern isnot generated even when the same NC program is executed, so applicationis not made to NC programs.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a numerical controllerwhich enables learning control to be applied also to an ordinary NCprogram (ISO/EIA format).

The numerical controller in accordance with the present invention has alearning control function for creating and storing correction data onthe basis of position deviation in the same operation patterns, andcorrecting the position deviation at the time of execution of the sameoperation pattern on the basis of the correction data. Commands in an NCprogram are executed, learning control is started at a location wherethe same operation pattern starts occurring, and learning control isstopped at a location where the same operation pattern ends.

The embodiments of the numerical controller of the present inventionhave the following functions.

From among the commands in the NC program, commands which produce thesame operation pattern to allow learning control or commands which donot allow learning control are discriminated from others and stored inadvance, and it is determined automatically whether the location iswhere the same operation pattern starts occurring or where the learningcontrol is stopped on the basis of the stored commands, so that learningcontrol is carried out for the section where the same operation patternoccurs.

Codes for specifying the learning control start position and thelearning control end position are provided, the learning control startposition and the learning control end position are specified using thecodes during the execution of the NC program, and learning control iscarried out from the learning control start position to the learningcontrol end position on the basis of the command codes.

The NC program is executed, ID codes are assigned to a plurality of sameoperation patterns that are generated, the correction data produced bylearning control is stored, and correction data for learning control isselected and learning control is carried out for each pattern on thebasis of the ID codes.

At the start and end of learning control, the correction value forcorrecting the position deviation is increased in a stepwise fashion atthe start of learning control, and is reduced in a stepwise fashion atthe end of learning control. The coefficient by which the correctionvalue is multiplied is varied in a stepwise fashion with respect to thecorrection value obtained from learning control, and the positiondeviation is corrected with the value obtained by multiplying thecorrection value by the coefficient.

The correction data of the learning control is automatically invalidatedwhen machining conditions have been modified.

A setting value for learning control when priority is placed on accuracyand a setting value for learning control when priority is placed onmachining velocity are provided, and accuracy priority or machiningvelocity priority can be selected.

Correction data for learning control, which is obtained by varying themachining conditions for a single type of workpiece and executing asingle NC program, is stored and any of the correction data may beselected to carry out learning control.

The correction data of the leatning control and the information in theNC program that carried out the learning control are stored, and thecorrection data of the learning control is also selected and setautomatically when the NC program is selected.

A function for notifying an external apparatus of the state of learningcontrol is provided.

A portion of or the entire NC program is a program for describing therelationship between the time and the position of a movable shaft, orthe relationship between the rotational angle of the spindle and theposition of the movable shaft.

In operation with an ordinary NC program (ISO/EIA format) in accordancewith the present invention, learning control is carried out in a sectionin which the same operation pattern is generated, so high precisionmachining can be carried out whereby the position deviation is reducedin machining with an ordinary NC program.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-described and other objects and characteristics of the presentinvention are made apparent in the description of the embodiments belowwith reference to the attached diagrams.

FIG. 1 is schematic diagram of the numerical controller of an embodimentof the present invention;

FIG. 2 is a portion of a block diagram of servo processing forcontrolling the servomotors, which is carried out by the processor, inthe servo system of the numerical controller shown in FIG. 1;

FIG. 3 is a flowchart of the preprocessing carried out eachpredetermined cycle by the processor of the CNC system of the numericalcontroller shown in FIG. 1;

FIG. 4 is a flowchart of the main processing carried out eachpredetermined cycle by the processor of the CNC system of the numericalcontroller shown in FIG. 1;

FIG. 5 is a flowchart of position loop processing and learning controlprocessing by the servo system, carried out by the processor of theservo system of the numerical controller shown in FIG. 1 eachpredetermined cycle;

FIGS. 6A to 6F are diagrams showing the reasons for varying the effectof learning control in a stepwise fashion, and general descriptions ofthe operation thereof; and

FIG. 7 is an example of a program in another embodiment in which thepresent invention is applied.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is schematic diagram of the numerical controller of an embodimentof the present invention. The hardware configuration of the numericalcontroller is the same as a conventional numerical controller, and istherefore shown in a simplified manner. The numerical controller 10 iscomposed of a CNC system 11, a servo system 12, and an interface 17 thatconnects the CNC system 11 and the servo system 12 together.

The CNC system 11 has a processor 13 for numerical control, memory 14composed of ROM, RAM, non-volatile RAM, or another type of memory, anddisplay/input unit 18 comprising a display composed a CRT or liquidcrystal and a keyboard or other input equipment. External memory 19 isconfigured so as to be connected to the CNC system 11 by way of aninterface.

The servo system 12 has a servo circuit for controlling the position,velocity, and electric current of the servo motor that drives the shaftsof machine tools and other equipment, and is provided with a controlcircuit for the spindle. Servo control for controlling the servomotor ofeach shaft, and control of the spindle are carried out through software.The servo system 12 has a processor 15 for the servo, and memory 16composed of ROM, RAM, or another type of memory. Servomotors M1 to M4for each shaft are connected to the servo system 12 by way of servoamplifiers 20. A spindle motor SM is connected to the servo system 12 byway of a spindle amplifier 21.

The processor 13 for the CNC system 11 reads and executes an NC programthat has been input via external memory 19 or the display/input unit 18and stored in the memory 14, performs distributed interpolationprocessing for each shaft on the basis of the movement commands that areissued in each block, and transmits movement commands to the servosystem 12 for each shaft via the interface 17. The processor 15 for theservo system 12 performs loop processing for position, velocity, andelectric current on the basis of the position/velocity feedback signalfrom the position/velocity detector provided to each servomotor andother equipment, as well as on the basis of the electric currentfeedback signal, and controllably drives the servomotors M1 to M4 foreach shaft by way of the servo amplifiers 20. Velocity feedback controlis carried out for the spindle motor SM in the same manner, and thespindle velocity is kept at the NC program command value.

The configuration and effect of the above-described numerical controller10 is the same as a conventional numerical controller, but the processor15 for the servo system 12 additionally carries out processing forlearning control in the present embodiment.

FIG. 2 is a portion of a block diagram of servo processing forcontrolling the servomotors M1 to M4, which is carried out by theprocessor 15 in the servo system 12. In particular, a learningcontroller 30 for carrying out learning control is provided in thepresent embodiment. The learning controller 30 is one that is well knownin the art, but differs from a conventional learning controller in thisembodiment in that the learning controller 30 is provided with a term 35for a coefficient α which is used for applying a stepwise processing(described later) to the correction value output from the learningcontroller 30.

When learning control is not carried out, the position feedback amountfed back from the position/velocity detector is subtracted in thesubtractor 36 from the position command transmitted from the CNC system11 to calculate the position deviation ε, the position deviation ismultiplied by the position loop gain Kp to calculate the velocitycommand, and the resulting velocity command is transmitted to thevelocity control unit. Proportioning, integration, and other processingis performed in the velocity control unit on the basis of the velocitycommand and the velocity feedback amount that was fed back, and theelectric current command is output to the electric current control unit.Loop control for the electric current is performed based on the receivedelectric current command, and the servomotors M1 to M4 are driven andcontrolled by way of the servo amplifiers 20.

The learning controller 30 has an adder 31, a band-stop filter 32provided for stabilizing the control system, a delay element memory 33for storing the correction data of the number corresponding to thesampling number of a single cycle of the same command pattern, a dynamiccharacteristic correction element 34 for compensating for the phasedelay and reduced gain of the control object, and a term 35 for thecoefficient α, as shown in FIG. 2.

The position deviation is calculated each sampling cycle(position/velocity loop processing cycle). Correction data correspondingto the current sampling in the same command pattern is read from thedelay element memory 33 each sampling cycle, the correction data thusread is multiplied by the coefficient α (when the hereinafter-describedstepwise processing is not performed, the coefficient α is 1, or theterm 35 for the coefficient α is not provided) following processing ofthe dynamic characteristics compensation element 34, and the product istaken as the output (correction value) of the learning controller 30.The output of the learning controller 30 and the position deviationdescribed above are then added by the adder 37, and the added value ismultiplied by the position loop gain Kp to calculate the velocitycommand Vc. The calculated velocity command Vc is input to the velocitycontrol unit 39.

The correction data read from the delay element memory 33 in the currentsampling is added to the position deviation in the adder 31, and theadded value is processed by the band-stop filter 32. The data stored inthe delay element memory 33 is then shifted a single place, and theoutput (correction data) of the band-stop filter 32 is stored in thememory area for storing the newest data.

As described above, of the correction data calculated based on theposition deviation at each sampling in the processing of the samecommand pattern previously executed, the correction data in the currentsampling at the time when the same command pattern is carried out isread out in learning control. The position deviation is corrected withthe correction data that is based on the read correction data, thecorrection data is stored in the delay element memory 33 as correctiondata for the corresponding sampling when carrying out the next samecommand pattern, and the correction data in the delay element memory 33is updated thereby. In other words, it is assumed that the sameoperation pattern will be generated by the same command pattern in orderto carry out learning control.

However, it is not always the case that the same operation pattern willbe generated when an ordinary NC program (ISO/EIA format) is repeatedlyexecuted. The action timing becomes offset each time the NC program isexecuted when screw thread-cutting, M-coding, or other commands aregiven, and the same operation pattern is not carried out when the NCprograms are executed. The NC program, on the other hand, may have asection in which the same operation pattern is repeatedly generated whenexecuting programs with a continuous stream of commands. In a section inwhich linear interpolation commands, circular interpolation commands, orother commands, for example, occur in a continuous fashion, themachining timing in this section is the same as long as the machiningconditions do not vary when the NC programs are executed, and the sameoperation pattern is repeatedly generated.

In view of the above, the processing executed by the NC program in thepresent invention is designed so that learning control is carried outautomatically or by a program command only in the section in which thesame operation pattern is performed.

First, described below is an embodiment for determining whether or not acommand allows learning control, and for automatically determining thesection in which learning control is carried out by NC program command.

The commands of an NC program, designed to repeatedly carry out the samecommand (operation) pattern with the same timing after processing hasstarted by a command, are set and stored in advance as commands thatallow learning control. In the section in which linear interpolationcommands, circular interpolation commands, or other commands are carriedout in a continuous fashion, the same command pattern is carried outwith the same timing to generate the same operation pattern, forexample, so the linear interpolation commands, circular interpolationcommands, or other commands are set and stored in the NC program ascommands that allow learning control. In a reverse arrangement, it ispossible to set and store commands incapable of learning control in theNC program, whereby commands which are not set and stored can bedetermined to be commands capable of learning control.

FIG. 3 is a flowchart of the preprocessing carried out each cycle (eachpreprocessing cycle) by the processor 13 of the CNC system 11.

First, a single block is read (step a1) from the NC program, adetermination (step a2) is made as to whether a command in that block isa program end command or not, and if not a program end command, then adetermination (step a3) is made as to whether a command for changing themachining conditions has been input or not. When the program,parameters, offset, override value of the feed velocity, or otherfactors have been changed to vary the machining conditions, the commandpattern (operation pattern) differs as a result, and the correction dataproduced by learning control carried out to the current point no longerretains any significance. Therefore, output is made to the servo system12 so that the correction data stored in the delay element memory 33 ofthe learning controller 30 is cleared in step a4.

If there is no change in the machining conditions, then a determination(step a5) is made as to whether or not parameters have been set thatmake automatic determination of learning control valid, and if theparameters have not been set in the learning control automaticdetermination mode, then analysis processing of the current block isperformed (step a9) and the process returns to step a1. Processing inwhich this learning control is not carried out is repeated thereafter.

When it has been determined that the parameter for making automaticdetermination of learning control valid has been set in step a5, then adetermination is made (step a6) as to whether the flag F indicating thatlearning control is ON has been set or not, and if learning control isnot ON, then a determination is made (step a10) as to whether thecommand read in step a1 is a command that allows learning control ornot. In other words, it is determined whether the read command is one ofthe established commands that allow learning control. If the commanddoes not allow learning control, then the process skips to step a9, andthe normal processing described above is carried out.

If the read command is not a command that allows learning control, then1 is added to the value of the counter for counting the ID code, andthis value is taken as the ID code for this command and stored (stepa11) together with the block. The counter that counts the ID code isinitially set to “0.” The flag indicating that learning control is ON isset, the learning control ON-state is stored (step a12) together withthe block, the process skips to step a9, analysis processing for thisblock is carried out, and the process returns to step a1. The processing(steps a1 to a6) described above is then carried out, and the learningcontrol ON flag, which was set by the processing in step a12 of theprevious cycle, (F=1) is set in step a6, so the process advances fromstep a6 to step a7, and a determination is made as to whether or not thecommand read in step a1 is a command that does not allow learningcontrol. In other words, a determination is made as to whether or notthe command that was read is a command that is established as a commandthat allows learning control. If the command is not one that does notallow learning control (a command that allows learning control), theprocess skips to step a9, and learning control is kept ON.

Learning control is thereafter kept ON as long as a command that doesnot allow learning control is not read. When it has been determined thatthe command read in step a7 is a command that does not allow learningcontrol, the learning control ON flag is set to OFF, the learningcontrol OFF-state is stored (step a8) together with the block, and theprocess advances to step a9.

The processing of steps a1 to a6, a10, and a9 is thereafter repeatedlycarried out until a command that allows learning control is read. Theprocessing from step a10 through steps all and a12 is then performedwhen a command that allows learning control is read again, the ID codeand the learning control ON-state are stored together with the block,the learning control flag is set to ON, and preprocessing is carriedout. When a command that does not allow learning control is read (stepa7) as each block is read, the learning control flag is set to OFF (stepa8) and learning control OFF-state is stored together with the block.

In the preprocessing stage of the NC program as described above, when acommand that allows learning control is read, the ID code and learningcontrol ON-state are stored together with the current block; and when acommand that does not allow learning control is read, on the other hand,learning control OFF-state is stored together with the current block.

When an instruction to end the program is read by the NC program, thecounter for counting the ID code is cleared (step a13) and thepreprocessing of the NC program is ended.

FIG. 4 is a flowchart of the main processing carried out each cycle(each main processing cycle) by the processor 13 of the CNC system 11.

In the preprocessing stage as described above, distributed interpolationprocessing is carried out for each shaft on the basis of the data thathas been analyzed and rendered executable by an NC program command. Inthis embodiment, the configuration allows a selection of whether or notto carry out a processing routine (“stepwise processing”) wherein theeffect of learning control is increased or decreased in a stepwisefashion in order to alleviate the mechanical shock that is potentiallygenerated when learning control starts and ends. In other words, theconfiguration allows a selection of whether to perform processing thatvaries the value of the coefficient α shown in FIG. 2 in a stepwisefashion, or to fix the value to “1” (or to carry out the processing ofthe learning controller 30, which does not has a term for thecoefficient α).

First, described below is the processing (stepwise processing;processing for varying the coefficient α in a stepwise fashion) forvarying the effect of the learning control in a stepwise fashion.

FIGS. 6A to 6F are diagrams showing the reasons for varying the effectof learning control in a stepwise fashion, and general descriptions ofthe operation thereof.

It is assumed that a position command such as that shown in FIG. 6A hasbeen output. In FIG. 6A, the horizontal axis represents time, and thevertical axis represents the command movement amount (per fixed unit oftime). (Hence, the vertical axis represents the command velocity). Whenlearning control is not performed, position deviation such as that shownin FIG. 6B is generated. In FIG. 6B the horizontal axis and the verticalaxis represent time and position deviation, respectively.

Here, it is assumed that learning control is ON from time t1 to t2, asshown in FIG. 6C. Learning control stores the value based on theposition deviation generated in the operation of the pattern carried outearlier, as correction data, in the same command pattern, and corrects(refer to FIG. 2) the position deviation of the current pattern beingexecuted with the aid of the stored correction data, so the positiondeviation is brought to a value that is approximately “0.” For thisreason, the position deviation rapidly decreases when learning controlis switched ON at time t1, and position deviation rapidly increases whenlearning control is switched OFF at time t2, as shown in FIG. 6D. Thevelocity command is a product of multiplying the position deviation bythe position loop gain Kp, so if the position deviation changes rapidly,then the velocity command also changes rapidly in accordance therewith.As a result, a shock is generated as the machine attempts to follow therapid change in the velocity command.

In view of the above, the effect of learning control is made to changein a stepwise fashion in the present embodiment, as shown in FIG. 6E. Aterm for the coefficient α is provided to the learning controller 30, asshown in FIG. 2, and the effect of correcting the learning control isalleviated by increasing or reducing the value of the coefficient α in astepwise fashion. As a result, the position deviation is reduced orincreased in a stepwise fashion to alleviate the shock, as shown in FIG.6F.

Referring once again to the main processing shown in FIG. 4, theprocessor 13 of the CNC system 11 performs processing for distributingthe movement command to each axis in the same manner as prior art on thebasis of the data in the block analyzed in the preprocessing shown inFIG. 3. Next, a determination (step b2) is made as to whether or not theparameter has been set so as to validate stepwise processing, and if theparameter has not been set so as to allow stepwise processing, theprocess skips to step b13, and data distributed in a conventional manneris output to the servo system 12. However, when an ID code and learningcontrol ON/OFF signal are added to the block, the ID code and learningcontrol ON or OFF signal are also transmitted to the servo system 12.

When stepwise processing is valid, a determination is made (step b3) asto whether or not learning control OFF data has been added to theanalyzed block.

When learning control OFF data is not read, a determination issubsequently made (step b4) as to whether learning control data ON hasbeen read or not, and if this data is also not read, then adetermination is made (step b5) as to whether the flag F1 indicatingthat learning control is ON is “1” or not. If the flag F1 is not “1,”then the process skips to step b13. In other words, a command thatallows learning control has not yet been read, so processing is carriedout in a conventional manner in that the data distributed in step b1 isoutput to the servo system 12.

When it has been determined in step b4 that learning control ON data hasbeen read, the flag F1 indicating that learning control is ON is set(the flag F1 is initially set to “0”) to “1,” and the timer T1 is resetand started (step b14). The time set for processing (stepwiseprocessing) that varies the effect of learning control in a stepwisefashion is set (step b15) in the timer T2, and the process advances tostep b13. Learning control ON data has been read at this time;therefore, in step b13, this learning control ON data and the ID codestored together with the data are output to the servo system 12 togetherwith data distributed in step b1.

In the next cycle, the flag F1 indicating that the learning control isON is set to “1,” so the process advances from step b5 to step b6, and adetermination is made as to whether or not the time recorded in thetimer T1 has reached the start position for stepwise processing to bedone when learning control is switched OFF, which is stored inassociation with the ID code of the learning control currently beingcarried out. The start position for stepwise processing is stored inassociation with the ID code by the processing in the later-describedsteps b17 and b18. This start position is not yet started at the timewhen the NC program is first executed, and for this reason, theresulting determination in step b6 is “No” and the process advances tostep b7.

In step b7, a determination is made as to whether the time set in timerT2 in step b15 has expired or not, and if the time has expired, then aset predetermined amount is subtracted (step b8) from the timer T2.Next, a determination is made as to whether or not the flag F2 is set to1, indicating that stepwise processing to be done when learning controlis switched OFF is being carried out. The flag F2 is initially set to“0,” therefore the process advances to step b10 and the coefficient αfor stepwise processing to be done when learning control is switched ONis calculated. The coefficient α is, for example, calculated by theequation α=(ts−t)/lts, wherein ts is the value set in step b15 and t isthe current value of the timer T2 subtracted in step b8.

The coefficient α calculated in this manner is transmitted to the servosystem 12 and set as a value that is multiplied by the correction dataof the learning controller 30. The process advances to step b13 and thedistributed processing data is output to the servo system 12.

The processing of steps b1 to b10, bl2, and bl3 is performed thereafterfor each cycle, the coefficient α is gradually increased. When thecoefficient α reaches “1,” and the timer T2 expires, the process skipsfrom step b7 to step 13, the output of the coefficient α is stopped, andthe coefficient α is fixed at “1.” The processing of steps b1 to b7, andstep b13 is repeated thereafter.

In step b3, if it is determined that data indicating that learningcontrol is OFF has been read, whereupon the set time is subtracted fromthe current value of the timer T1; the start position (elapsed time fromthe start of learning control) for stepwise processing, performed duringthe OFF-state of learning control and used in the subsequent executionof the NC program, is calculated (step b17); and the calculated startposition for stepwise processing is stored (step b18) together with theID code. The flags F1 and F2 are both set to “0” (step b19). The processthen advances to step b13, and the distributed processing data isoutput, but in this case, the data indicating that learning control isOFF is output to the servo system 12.

The start position for stepwise processing to be done at the time whenlearning control is OFF is stored together with the ID code in step b18,so in the subsequent execution of the NC program in step b6, adetermination is made as to whether or not the value of the timer T1 hasreached the start position for stepwise processing to be done whenlearning control is switched OFF, which corresponds to the current IDcode. If the start position has been reached, then the flag F2indicating that stepwise processing to be done when learning control isswitched OFF is being carried out is set to “1” (step b16), and the settime is set in the timer T2 (step b15). From the next cycle, theprocessing of steps b1 to b9 is carried out, and the flag F2 is thendetected to be “1” in step b9, so the process advances to step b11, andthe coefficient α for the state in which learning control is OFF iscalculated and output (step b12) to the servo system 12.

The coefficient α for the state in which learning control is OFF iscalculated with the equation α=t/ts, wherein ts is the value set in stepb15 and t is the current value of the timer T2 subtracted in step b8.When data indicating that learning control is OFF is read, then theprocess advances from step b3 to step b17 and the above-describedprocessing is carried out.

As described above, the coefficient α for increasing or decreasing theeffect of learning control in a stepwise fashion is calculated and sentto the servo system 12.

The processor 15 for the servo system 12 carries out the processingshown in FIG. 5 each predetermined cycle (or each position/velocity loopprocessing cycle).

A determination is made (step c1) as to whether or not there is dataindicating that learning control is to be switched ON in the data sentfrom the CNC system 11. If data indicating that learning control is tobe switched ON has not been sent, then a determination is made (stepc12) as to whether or not data indicating that learning control is OFFhas been sent, and if this data has also not been sent, then processing(step c4) for calculating the position deviation ε is performed in aconventional manner from the feedback amount of the position and thecommand position that has been sent.

Next, a determination (step c5) is made as to whether the flagindicating that learning control is ON is “1” or not. If the flag is not“1,” then the velocity command Vc is calculated (step c10) bymultiplying the position deviation ε by the position loop gain Kp in thesame manner as in the prior art, and the velocity command Vc is outputto the velocity command unit. Proportioning, integration, and othertypes of velocity loop processing are performed in the velocity controlunit on the basis of the velocity command Vc and the velocity feedbacksignal. This processing is the same as in the prior art, so adescription thereof is omitted.

The above description is that of position loop processing in the servosystem 12 when learning control is not being performed. When dataindicating that learning control is ON is read in step c1, the set ofcorrection data stored in correspondence with the ID code sent togetherwith the data is read (step c2). In other words, read is the set ofcorrection data (the correction data of the number corresponding to thesampling number of a single cycle) stored in the delay element memory 33of the learning controller 30 in FIG. 2, which is the data stored foreach ID code using the first-in first-out format (FIFO). As any set ofcorrection data has not yet been created when the NC program is firstexecuted, a memory for storing correction data for the ID code is justprepared in this case. Next, the flag indicating that learning controlis ON is set to “1” (step c3), and the position deviation E iscalculated (step c4) from the feedback amount of the position and thecommand position that have been sent.

As the flag indicating that learning control is ON is set to “1” (stepc5), the first correction data (the first stored data (oldest data)) isread from the correction data that is read in step c2, and dynamiccharacteristics compensation processing is carried out in a conventionalmanner to calculate the correction value y (step c6).

Further, the stored coefficient α that has been output from the CNCsystem 11 is multiplied by the correction value y to calculate the stepcorrection value y′ (step c7). The read correction value y is added tothe position deviation E calculated in step c4, the added value (ε+y) isprocessed in the band-stop filter 32 shown in FIG. 2 to calculate thecorrection data, and the result is stored as the newest correction data.A set of correction data is updated in this manner (step c8).

Also, by adding the step correction value y′ calculated in step c7 tothe position deviation ε calculated in step c4, the position deviationis corrected (step c9) by learning control, the position loop gain Kp ismultiplied by the position deviation for which correction has been madeto calculate (step c10) the velocity command Vc, and the calculatedvelocity control Vc is transmitted to the velocity control unit.

From the next cycle, the processing of steps c1, c12, c4, and c5 to c11is repeatedly carried out. When data indicating that learning control isOFF is read, the process advances from c12 to c13, the flag indicatingthe learning control is ON is set to “0,” the process advances to stepc4, and the processing of step c4, step c5, and steps c10 to c11 iscarried out. From the next cycle, the processing of step c1, step c12,steps c4 and c5, and steps c10 to c11 is carried out because the flagindicating the learning control is ON is set to “0.”

As described above, by setting the parameters so that learning controlis automatically started from this command and stepwise processing isperformed when a command that allows learning control is read by the NCprogram, the correction value produced by learning control is applied soas to increase in a stepwise fashion when learning control is ON, whilethe correction value produced by learning control is applied so as todecrease in a stepwise fashion when learning control is OFF.

In the embodiment described above, whether to start or end learningcontrol from a command in the NC program is automatically determinedfrom the type of program command, but the determination is notnecessarily automatically made from the type of programmed command. Alearning control ON command (Gaaa, for example) and a learning controlOFF command (Gbbb, for example) may be issued (aaa and bbb are numbersin G code) in the NC program, and the IC code may be issued togetherwith the learning control ON command (Gaaa). (A counter may be provided,and the ID code may be determined based on the number of learningcontrol ON commands counted from the beginning of the NC program.) Inthis case, the determinations made in step c7 and step c10 of FIG. 3replace the determination as to whether the command is a learningcontrol OFF command or a learning control ON command.

In the embodiment described above, when the feed velocity, offset value,or other machining conditions have changed in step a3 of FIG. 3, thecorrection data for learning control is cleared by the processing instep a4, so the correction data for learning control in new machiningconditions can be automatically created. It is also possible to transmitand store the correction data for learning control created with variousmachining conditions in the memory in the CNC system 11, to read thecorrection data corresponding to the machining conditions when required,to transmit the data to the servo system 12, and to use the correctiondata. The correction data may also be output and stored in externalmemory 19. Shorter learning time can be ensured by inputting data to thenumerical controller 10 and using the stored correction data. An ID codeis assigned to the same operation pattern that performs learningcontrol, and the correction data of the learning control is stored, soan ID code may be specified and learning control may be carried out foronly the operation pattern of the specified ID code.

By adding to the ID code information that differs according to machiningconditions or the like at the time when learning is carried out,learning control can be immediately performed by specifying thecorrection data of the learning control that corresponds to themachining conditions at that time through the use of external signals,NC program parameters, or other methods when the same type of work is tobe carried out.

By also storing NC program information that has carried out the learningcontrol together with the ID code, the correction data for learningcontrol can also be simultaneously selected when the NC program to beexecuted is selected.

Learning control brings the position deviation to approximately zero byrepeatedly carrying out the same command pattern, and when externaldisturbances are considerable, as in rough machining and high velocitymachining, a phenomenon occurs whereby learning control does notstabilize. In this case, stabilized machining can be carried out, evenin rough machining or high speed machining, by varying learning controlsettings such as changing the bandwidth of the band-stop filter 32 ofthe learning controller 30 so as to stabilize a control. In view of theabove, the settings for learning control can be changed for machiningvelocity priority when performing rough machining or high velocitymachining, or for accuracy priority when performing machining thatrequires accuracy. This can be achieved by varying the settings (theband-stop filter 32 setting, for example) of learning control, as whenthe coefficient α was varied.

The ON/OFF state of learning control and the state of position deviationmay be read from the servo system 12 to the CNC system 11, and the readdata may be displayed to the display screen of the display/input unit18. The range of the position deviation may be set in advance, and thepresence of position deviation within this range may be monitored.

In the embodiment described above, the portion for which the sameoperation pattern is carried out may be separated from the NC program,and learning control may be applied to that portion in an ordinary NCprogram, but-other than this type of NC program, the learning control ofthe present invention may also be applied when executing a program, suchas that shown, for example, in FIG. 7, in which an association is made,for example, between the positions on the X and Z axes of a feed shaftin relation to the rotational angle of the spindle.

In FIG. 7, <PATH TABLE> is a program name; S01, S11, and so forth arethe rotational positions of the spindle; X01, X11, and so forth are thepositions of the movable X shaft; and Z01, Z11, and so forth indicatethe positions of the movable Z shaft. “S11 X11 Z11” show that when S11is the rotational angle of the spindle, X11 is the position of themovable X shaft, and Z11 is the position of the movable Z shaft.

The positions of the movable shafts may be specified with reference totime instead of the rotational position of the spindle.

1. A numerical controller having a learning control function forcreating and storing correction data on the basis of position deviationin the same operation patterns, and correcting the position deviation atthe time of execution of the same operation pattern on the basis of thecorrection data, wherein commands in an NC program are executed,learning control is started at a location where the same operationpattern starts occurring, and learning control is stopped at a locationwhere the same operation pattern ends.
 2. The numerical controlleraccording to claim 1, wherein, from among the commands in the NCprogram, commands which produce the same operation pattern to allowlearning control or commands which do not allow learning control arediscriminated from others and stored in advance, and it is determinedautomatically whether the location is where the same operation patternstarts occurring or where the learning control is stopped on the basisof the stored commands, so that learning control is carried out for thesection where the same operation pattern occurs.
 3. The numericalcontroller according to claim 1, wherein codes for specifying thelearning control start position and the learning control end positionare provided, the learning control start position and the learningcontrol end position are specified using the codes during the executionof the NC program, and learning control is carried out from the learningcontrol start position to the learning control end position on the basisof the command codes.
 4. The numerical controller according to claim 1,wherein the NC program is executed, ID codes are assigned to severaltypes of same operation patterns that are generated, the correction dataproduced by learning control is stored, and correction data for learningcontrol is selected and learning control is carried out for each patternon the basis of the ID codes.
 5. The numerical controller according toclaim 1, wherein, at the start and end of learning control, thecorrection value for correcting the position deviation is increased in astepwise fashion at the start of learning control, and is reduced in astepwise fashion at the end of learning control.
 6. The numericalcontroller according to claim 5, wherein the coefficient by which thecorrection value is multiplied is varied in a stepwise fashion withrespect to the correction value obtained from learning control, and theposition deviation is corrected with the value obtained by multiplyingthe correction value by the coefficient.
 7. The numerical controlleraccording to claim 1, wherein the correction data of the learningcontrol is automatically invalidated when machining conditions aremodified.
 8. The numerical controller according to claim 1, wherein asetting value for learning control when priority is placed on accuracy,and a setting value for learning control when priority is placed onmachining velocity are respectively provided to enable the selectionbetween the accuracy priority or machining velocity priority.
 9. Thenumerical controller according to claim 1, wherein correction data forlearning control, which is obtained by executing a single NC programwhile varying the machining conditions for a single type of workpiece,are stored in advance, so that learning control can be carried out byselecting any of the correction data.
 10. The numerical controlleraccording to claim 1, wherein the correction data of the learningcontrol and the information in the NC program that carried out thelearning control are stored, and the correction data of the learningcontrol is also selected and set automatically when the NC program isselected.
 11. The numerical controller according to claim 1, having afunction for notifying an external apparatus of the state of learningcontrol.
 12. The numerical controller according to claim 1, wherein theentire NC program or a part thereof is a program describing therelationship between the time and the position of a movable shaft, orthe relationship between the rotational angle of the spindle and theposition of the movable shaft.